Memory media carrier and method of manufacture

ABSTRACT

A carrier for storing a plurality of memory devices therein and a method of manufacture for the carrier are provided. The carrier includes a jacket having a plurality of interconnected panels. A hinge member is applied to a hinge edge of containers and at least a portion of one of the panels of the jacket to mount a stack of containers within the jacket.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a Continuation In Part of application Ser. No. 11/164,581 filed Nov. 29, 2005 and titled Memory Media Carrier and Method of Manufacture the entire disclosure of which is incorporated herein by reference.

BACKGROUND OF THE INVENTION

The sale to consumers of memory media, for example, CD's and DVD's is popular and demand is growing. Until recently, most memory media was sold and distributed in singles i.e., a single media device in a package. Such memory media typically contained movies or music. Recently, however, multi packs of memory media have grown in popularity. For example, for some long movies, multiple DVD discs were needed to contain the entire movie and promotional material. Additionally, many television series are now sold on memory media having an entire season sold in a single package requiring multiple discs. Many devices have been provided for the sale of multi-pack memory media. One example of such a package is a sleeve assembly with each of the memory media being stored in a respective tray or other holder and the trays are not connected together but individually inserted into the sleeve for storage. In order to extract an appropriate memory media, the entirety of the stack is removed to determine which individual tray contains the desired memory media. A package for holding a plurality of memory media is disclosed in U.S. Patent Publication No. U.S. 2003/0106814 published Jun. 12, 2003. This patent discloses a package having a jacket comprised of a plurality of interconnected panels including a front panel, rear panel and spine panel. A stack of trays is hingedly connected together by an adhesive sided hinge member which is applied to the trays when the trays are positioned in an elongated stack or row with the strip of adhesive material being applied across the hinge edges of the trays. The joined trays are then being separated into smaller stacks by a suitable cutter. This requires an indexing mechanism to ensure that the appropriate number of and the correct trays, if the trays already contain the memory media. Each stack of trays is then secured to a single panel of a respective jacket. Each of the trays may then be individually hingedly moved about the hinge member. The hinge member is connected only to the hinge edges of the trays. This is necessitated by the method of manufacture and the associated cutting device for separating the hinge strip into segmented sections each segment securing a respective stack of trays together.

Another problem with current multi disc packages such as that discussed above is the requirement for gluing one of the disc trays to a package panel. Not only is a separate processing step required, the gluing of a tray to a panel eliminates that panel from use to present graphical information, text information since the tray covers and hides at least a significant portion one of the surfaces of one of the panels. It would be desirable to provide a package that utilizes the simple to use hinge tape for hinged movement of the trays relative to one another and in addition uses the hinge tape to mount the stack of trays to the jacket.

There is thus a need for an improved carrier for releasably mounting individual memory media in a single package containing a plurality memory of media devices.

SUMMARY OF THE INVENTION

The present invention provides a carrier for storing a plurality of individual memory media devices in a single package with each memory media device being individually removable. The carrier is constructed to provide individual access to a memory media device amongst a plurality of memory media devices stored therein by hingedly moving one storage tray relative to another storage tray. The carrier includes ajacket having a plurality of panels including a panel portion secured to a portion of a hinge member hingedly connecting the plurality of trays together. The hinge member may be a strip of material with adhesive on one side thereof which is attached to a hinge edge of each of the trays providing a hinge joint between each tray of a adjacent pair of trays. The panel portion mounts the hinge member at one edge margin to the jacket.

The present invention also involves the provision of a method of making a carrier for storing a plurality of memory devices wherein the method includes first forming a jacket having a plurality of panels including a panel portion. Preferably the jacket is formed as an integral structure with fold lines separating each of the panels from an adjacent panel. A plurality of stacks each containing a plurality of trays is provided with the stacks of trays moving through an assembly machine in end edge to end edge relationship. A strip of hinge material is applied to hinge edges of the trays in each stack with the hinge member preferably extending lengthwise along a stack of trays and then to a trailing stack of trays also along its length. The hinge member is applied to the hinge edges to hingedly connect the stack of trays together. Adjacent stacks of trays are separated from one another. The hingedly connected stack of trays is then mounted to the panel portion of the jacket wherein the stack of trays is movable relative to an underlying panel for selective exposure of a face of the underlying panel.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a carrier including a plurality of hingedly connected storage trays adapted for releasably mounting a memory device within the carrier assembly.

FIG. 2 is an enlarged fragmentary view of a hinge portion connecting the stack of trays together with its overlying panel member.

FIG. 3 is an end view of the carrier shown in an open condition.

FIG. 4 is a perspective view of the carrier of FIG. 1 but shown in a closed condition.

FIG. 5 is a perspective view of a modified form of carrier including a plurality of hingedly connected storage trays adapted for releasably mounting a memory device within the carrier assembly.

FIG. 6 is an enlarged fragmentary end view of a hinge connecting a stack of trays together.

FIG. 7 is an end view of the carrier shown in an open condition.

FIG. 8 is a perspective view of the carrier of FIG. 5 but shown in a closed condition.

Like reference numerals throughout the various Figures designate like or similar parts and structure.

DETAILED DESCRIPTION

The reference numeral 1 designates generally a carrier for use in containing for distribution and storage a plurality of memory media devices 3 such as CD's and DVD's that contain machine readable information, e.g., digital information such as music, movies, television shows and the like. A plurality of containers 5, are hindgedly attached to a hinge member 7 which is in turn secured to the jacket 9. The containers 5 are movable about gap bridging portions of the hinge member 7 allowing the stack to open up in a fan like manner to expose the media devices each within a respective container 5 for removal and/or reinsertion.

The jacket 9 is comprised of a plurality of panels that are connected to one another. In the illustrated structure, the panels include a front panel 11, spine panel 12, back panel 13 and an interior panel 14. The panels 11-14 may be formed of any suitable material as for example paperboard having a thickness on the order of about 0.01 inch to about 0.04 inch. Preferably the panels 11-14 are formed as an integral structure and may be die cut prior to formation from a single sheet of paperboard. The panels 11-14 may be single layer or multiple layers as desired. In the illustrated structure, the front panel 11 is a multi layer panel preferably formed by having portions 11A, 11B, 11C secured to one another at interengaging faces and formed by folding at an outer edges 16A, 16B, 16C and having inner and outer surfaces 11D, 11E. Likewise, the back panel 13 may be multi-layered with the layers 13A, 13B being secured at interengaging faces and connected at edge 17 and providing inner and outer surfaces 13C, 13D. The spine panel 12 is connected to each of the front panel 11 and back panel 13 at the fold lines 18, 19. The interior panel 14 is preferably an extension of one of the panels 11-13 and is shown as an extension of the panel 13 joined together at the fold line 20. Another panel 22 may be provided extending from a portion of the front panel 11 to provide a removable tab or tabs 21 for such things as proof of purchase, discounts and the like. The panel 22 is joined to the front panel 11 at fold line 23. While the interior panel 14 is shown as connected to the back panel 13 along an interior fold line 20, it is to be understood that it may also be connected to a top edge or outside edge of any of the panels that provide for different folding arrangements as desired. For example, the interior panel 14 may be connected to an outer edge 24, a top or bottom edge 25, 26 of the back panel 13 or spine panel can be mounted to the front panel 11.

A pocket 27 may be provided between portions 11B, 11C. The containers 5 for DVD's and CD type media devices are typically in the form of a molded tray and are made of a polymeric material, e.g., styrene or polystyrene and may be clear. The containers 5 have a recess 30 for receipt therein of a respective media device 3 which may be mounted on a post 31 located in the recess 30 and projecting from a bottom surface thereof into the recess. The containers 5 have a thickness and an outer perimeter. The outer perimeter is defined by a plurality of side or end edges 32A-D having height substantially the same as the thickness of the container 5. One of the edges 32 is utilized as a hinge edge for the securement of the hinge member 7 thereto. The containers 5 are in a stack having the hinge edges which is noted as 32A in the drawings, aligned and define a plane. When the carrier 1 is folded to a closed condition the hinge member 7 is secured to the hinge edges 32A and extends between the edges 32B, C which extends from opposite ends of the hinge edge 32A. The edge 32D is a distal edge while the hinge edge 32A is a proximal edge. Preferably, the corresponding edges 32A-D of each container 5 also define a plane and are aligned as are the edges 32A. That is, the edges 32B are aligned, the edges 32C are aligned and the edges 32D are aligned.

The hinge member 7 is preferably a polymeric strip or tape having adhesive preferably on one face 35 thereof. By having adhesive pre-applied to the hinge member 7, the installation of the hinge member adhesively to the edges 32A of containers 5 can be facilitated and preclude, adhesive from flowing between the containers possibly interfering with their hinged movement relative to one another. However, it is to be understood that adhesive could be applied to the edges 32A and a flexible hinge member 7 be adhesively secured thereto. The hinge member 7 may be made of polyethylene, polypropylene or any other suitable flexible polymeric material. Other materials can be used to construct the hinge member 7 including paper and composites depending upon the strength needed and the number of flex cycles anticipated for the hinge member 7. The hinge member 7 bridges the gaps 37 between adjacent containers 5 forming a hinged joint between each of the adjacent containers 5. In a preferred embodiment, the hinge member 7 has adhesive applied to both the face 35 and its opposing face 36. However, it is to be understood that adhesive could be applied to one face 38 of the interior panel 14 or to face 36 of the hinge prior to its securement to the face 38 of the panel 14. The interior panel 14 is then used to at least partially mount a stack container 5 in the jacket 9 and also serves the function of reinforcing at least a portion of the hinge 7. While the interior panel 14 is shown as being secured to each of the edges 32A of all the containers 5 to bind them together, it may be secured to one or more as desired. However, it is preferred that the interior panel 14 be secured to all of the container 5 at least to the extent that it bridges the gaps between the containers 5 to reinforce the hinge joints 39 between the containers 5. In a preferred embodiment an element is provided to assist or bias the panel 14 to bend or hinge at the gaps 37. Lines of perforations 39 can be provided at the gaps 37. The perforations 39 may go through the panel 14 or partially through the panel 14. A crease line may be provided with or instead of the perforations 39. Score lines may also be provided.

In a preferred embodiment, the stack of containers 5 is secured to a plurality of panels with one of the panels preferably being the panel 14. As shown, the stack of containers 5 is also secured to the back panel 13 as with adhesive 41. Other forms of attachment may be used if desired. As shown, the adhesive 41 is applied to a face 42 of the panel 13 with the adhesive being positioned to adhere to portions of a container 5 abutting the face 42. Spot depositing of the adhesive 41 is preferred to reduce the amount of adhesive used for securement. A hot melt adhesive can be used.

The present invention also includes a method of making a carrier for storing a plurality of memory devices. In a preferred embodiment, a plurality of sets of stacks of containers 5 are formed. The appropriate number of carriers is positioned in each stack and the stacks are arranged in end to end relationship along a conveyor. The hinge edges 32A preferably are positioned facing upwardly or otherwise exposed for the application of the hinge member 7 thereto. Preferably the hinge member 7 is formed from an elongate strip of material which may be cut into proper length segments either before application to the hinge edges 32A or after application. The plurality of stacks of trays are positioned in end edge to end edge relationship and preferably abut one another when the hinge member 7 is applied in the form of a continuous strip and cut after application to the hinge edges 32A. A completed jacket is then positioned where the panel 14 overlies the hinge member 7 and is then applied, to its respective hinge member 7. The adhesive on the opposite faces of the hinge member 7 is preferably a pressure sensitive adhesive wherein securement is effected by applying force to the panel 14 which will help secure the panel 14 to the hinge member and the hinge member to the hinge edges 32A of the containers 5. The jackets 109 are extracted from a magazine storing a plurality of jackets. Prior to depositing in the storage magazine, the jackets are suitably formed. The material comprising the jackets 9 is suitably cut as for example die cutting, laser cutting or the like. The various panels are then formed by forming the various crease lines therebetween. In the event of a multi layer panel for example the front panel 11 and the back panel 13, they are folded along the edges for example the edges 16A-C and 17, wherein the faces are adhesively secured together as for example with pressure sensitive adhesive or hot melt adhesive. Each of the panels 11, 12, 13 and 14 have generally opposite surfaces. Some of the surfaces for example the surfaces 11D and 13C will be on the interior of the jacket 9 when in a closed condition and the surfaces 11E and 13D will be on the exterior of the jacket when the jacket is in a closed condition. The surfaces may be provided with graphic elements for example the name of the set, advertising graphics, promotional graphics, and marketing graphics as is well known in the art. The graphics will be printed on the panels at any suitable time during the formation of the jacket which can be either after forming the multi layer panels or before folding the cut blank. The sequence of attaching the stack to the two panels may be in the order of securing first to the panel 14 and then the back panel 13 or the back panel 13 and then the binder panel 14 depending upon the particular construction of the assembly line. The panels 11, 12, 13, 14 and 22 are preferably formed as an integral structure from a cut blank. Simple folding of the blank to form the jacket 9 may be easily accomplished.

The reference numeral 101 designates generally a modified form of the carrier 1, as illustrated in FIGS. 5-8, for use in containing, for distribution and storage, a plurality of memory media devices 103, such as CD's and DVD's that contain machine readable information, e.g., digital information such as music, movies, television shows and the like. A plurality of containers 105 are hingedly attached to a hinge member 107 which is in turn secured to the jacket 109. The containers 105 are movable about gap bridging portions of the hinge member 107 allowing the stack to open up in a fan like manner (FIG. 6) to expose the media devices 103 each within a respective container 105 for removal and/or reinsertion.

The jacket 109 is comprised of a plurality of panels that are connected to one another. In the illustrated structure, the panels include a front panel 111, spine panel 112, back panel 113 and panel portions 114A, 114B extending from the spine panel 112 with the panel portion 114A being connected to the spine panel 112 at fold line 119 and the panel portion 114B being part of the back panel 113. The panels and panel portions 111-114 may be formed from any suitable material as for example paperboard having a thickness on the order of about 0.01 inch to about 0.04 inch. Preferably, the panels and panel portions 111-114 are formed as an integral structure and may be die cut (or otherwise suitably cut) prior to formation from a single sheet of paperboard or the like. The panels and panel portions 111-114 may be single layer or multiple layers as desired. In the illustrated structure, the front panel 111 is a multi-layer panel preferably formed by having portions 111A and 111B secured to one another at interengaging faces and portion 111C overlying portion 111B and formed by folding at outer edges 116A, 116B, 116C and having inner and outer surfaces 111D, 111E respectively. Likewise, the back panel 113 may be multi-layered with the layers 113A, 113B thereof and preferably being secured at interengaging face portions and connected at edge 117 providing inner and outer surfaces 113C, 113D. The back panel 113 can be provided with an edge margin portion that includes panel portions 114A and 114B with the portion 114A preferably being a edge margin of the layer 113A and connecting to the spine panel 112 at fold line 119 and the portion 114B being an edge margin of layer 113B. The edges 114C, 114D are generally parallel to the fold line 119 and may be superposed when the jacket 109 is closed. The panel portion 114B overlies the panel portion 114A with an interface therebetween when the jacket 109 is closed. There may be a fold or crease line 115 between the panel portion 114A and the remainder of the panel 113 and is preferably generally parallel to the fold line 119. The spine panel 112 is connected to each of the front panel 111 and back panel 113 at the fold lines 118,119. A panel 122 may be provided and extends from a portion of the front panel 111 to provide a removable tab or tabs 121 for such things as proof of purchase, discounts and the like. The panel 122 is joined to the front panel 111 at fold line 123 but may be joined elsewhere. A pocket 127 may be provided between portions 111B, 111C as shown broken away in FIG. 5.

The containers 105 for DVD and CD type media devices are typically in the form of a molded tray that are made of a polymeric material, e.g., styrene or polystyrene and may be clear. The containers 105 each have a recess 130 for receipt therein of a respective media device 103 which may be mounted on a post 131 located in the respective recess 130 and projecting from a bottom surface thereof into the recess 130. The containers 105 have thickness and an outer perimeter. The outer perimeter is defined by a plurality of side or end edges 132A-D having heights substantially the same as the thickness of the container 105. One of the edges, 132A, is utilized as a hinge edge for the securement of the hinge member 107 thereto. The containers 105 are in a stack having the hinge edges, which are denoted as 132A in the drawings, aligned and defining a plane when the containers 105 are in a closed orientation as seen in FIG. 8. When the carrier 101 is folded to a closed condition as seen in FIG. 8, the hinge member 107 portion 107B attached to the edges 132A is generally parallel to the spine panel 112 and extends between the edges 132B, 132C which extend from opposite ends of the hinge edge 132A when the carrier 101 is closed, the spine panel 112 and hinge portion 107B are generally normal to the panel portion 114A, 114B and the hinge portion 107A. The edge 132D is a distal edge while the hinge edge 132A is a proximal edge. Preferably, the corresponding edges 132A-D of each container 105 also define a plane and are aligned as are the edges 132A, that is, the edges 132B are aligned, the edges 132C are aligned, and the edges 132D are aligned when the carrier 101 is closed.

The hinge member 107 is preferably a polymeric strip of tape having adhesive preferably on one face 135 thereof and optionally two faces as described below. By having adhesive pre-applied to the hinge member 107, the securement of the hinge member adhesively to the edges 132A of containers 105 can be facilitated and preclude liquid adhesive from flowing between the containers possible interfering with their hinged movement relative to one another. Additionally, the hinge member 107 is adhesively secured to the panel 113B at preferably an inside face of the panel portion 114B. When the carrier 101 is closed, the hinge edge margin portion 107A is captured between the panel portions 114A, 114B. It is to be understood, in the alternative, that adhesive could be applied to the edges 132A and a portion of the layer 113B and a flexible hinge member 107 can be adhesively secured thereto. The hinge member 107 may be made of polyethylene, polypropylene or any other suitable flexible polymeric material. Other materials can be used to construct the hinge member 107 including paper and composites depending upon the strength and the number of flex cycles anticipated for the hinge member 107. The hinge member 107 bridges the gaps (interface zones) 137 between adjacent containers 105 forming a hinge joint between each of the adjacent containers 105 and the container 105 overlying and abutting the surface 113C. In a preferred embodiment, the container 105 overlying and abutting the surface 113C is not secured to that surface and may move in a hinged manner relative thereto about a portion of the hinge 107 for exposure of the surface 113C. Additionally, in a preferred embodiment, the hinge member 107 may have adhesive applied to both the face 135 and its opposing face 136 so an additional layer of material 140 (shown in phantom in FIG. 6) may be adhesively secured to the hinge member 107 as in the above described structure for the form of invention shown in FIGS. 1-4. Such a multi-layered member is shown in phantom in FIG. 6. Additionally, the hinge member 107 may be secured to the panel portion 114 eliminating the fold line 115 if desired.

The form of the invention shown in FIG. 5-8 also includes a method of making a carrier for storing a plurality of memory devices. In a preferred embodiment, a plurality of stacks of containers 105 are formed. The appropriate quantity of carriers is positioned in each stack and the stacks are arranged in end to end relationship along a conveyor. The hinge edges 132A preferably are positioned facing upwardly or otherwise exposed for the application of the hinge member 107 thereto. Preferably the hinge member 107 is formed from an elongate strip of material which may be cut into proper length segments either before application to the hinge edges 132A or after application. A plurality of stacks of trays are positioned in end to end relationship and preferably abut adjacent stacks when the hinge member 107 is applied in the form of a continuous strip and cut after application to the hinge edges 132A. A completed jacket 109 is positioned adjacent a respective stack of trays with one of the containers 105 preferably abutting and overlying the surface 113C. A side edge marginal portion 107A of the hinge member 107 is positioned in overlying relationship to the portion 114B of the layer 113C and is folded and pressed into engagement with the layer 113C to effect the adhesive engagement therebetween. The adhesive used to secure the hinge member 107 to the containers 105 and the panel 113 is preferably a pressure sensitive adhesive wherein securement is effected by applying force to the margin portion 107A and the remainder of the hinge member 107 to effect the securement of the components together. The jackets 109 are extracted from a magazine storing a plurality of jackets. Prior to depositing in the storage magazine, the jackets 109 are suitably formed. The material comprising the jackets 109 is suitably cut as for example by die cutting, laser cutting or the like. The various panels of the jacket 109 are then formed by forming the various crease lines therebetween. In the event of a multi layer panel, for example, the front panel 111 and the back panel 113, they are folded along the edges for example the edges 116A-C and 117 wherein the adjacent overlying faces are adhesively secured together as for example with pressure sensitive adhesive or hot melted adhesive. Each of the panels 111, 112 and 113 and the panel portion 114 have generally opposite surfaces. Some of the surfaces for example the surfaces 111D and 113C will be on the interior of the jacket 109 when in a closed condition and the surfaces 111E and 113D will be on the exterior of the jacket when the jacket 109 is in a closed condition. The surfaces may be provided with graphic elements for example the name of the set, advertising graphics, promotional graphics, and marketing graphics as is well known in the art. The graphics will be printed on the various panels at any suitable time during the formation of the jacket which can be either after forming the multi-layer panels or before folding the cut blank from which the jacket 109 is formed. The panels 111, 112, 113 and 122 and the panel portion 114 are preferably formed as an integral structure from a cut blank. Simple folding of the blank to form the jacket 109 may be easily accomplished as is well known in the art.

Thus, there has been shown and described several embodiments of a novel invention. As is evident from the foregoing description, certain aspects of the present invention are not limited by the particular details of the examples illustrated herein, and it is therefore contemplated that other modifications and applications, or equivalents thereof, will occur to those skilled in the art. The terms “having” and “including” and similar terms as used in the foregoing specification are used in the sense of “optional” or “may include” and not as “required”. Many changes, modifications, variations and other uses and applications of the present construction will, however, become apparent to those skilled in the art after considering the specification and the accompanying drawings. All such changes, modifications, variations and other uses and applications which do not depart from the spirit and scope of the invention are deemed to be covered by the invention which is limited only by the claims which follow. 

1. A carrier for storing a plurality of individual memory devices, said carrier comprising: a jacket having a plurality of panels, including a front panel, a back panel, a spine panel and a panel portion, said front and back panels being connected to the spine panel and the panel portion being positioned adjacent a first side edge of the spine panel; a plurality of containers each having a hinge edge; a hinge member secured to each of the containers adjacent the hinge edge of the containers hingedly joining the containers in a stack, said stack of hingedly attached trays being attached to the panel portion wherein one surface of the panel portion overlying and being secured to an exposed surface of the hinge member at least partially mounting the stack to the jacket with the hinge edges being generally parallel to said first side edge.
 2. A carrier as set forth in claim 1 wherein the panel portion being part of said back panel.
 3. A carrier as set forth in claim 1 wherein the back panel, spine panel, panel portion and front panel being integral with one another.
 4. A carrier as set forth in claim 3 wherein the jacket is formed of paperboard.
 5. A carrier as set forth in claim 1 wherein the back panel drawing a plurality of layers and the panel portion being a portion of one of said layers.
 6. A carrier as set forth in claim 1 wherein the plurality of layers including on outer layer and at least one inner layer, said panel portion being a portion of the inner layer.
 7. The carrier of claim 6 wherein the hinge member including a strip of material with adhesive applied on opposite faces of the strip prior to attachment to the containers.
 8. The carrier of claim 7 including a reinforcing member secured to a face of the strip.
 9. The carrier of claim 6 wherein the hinge member having a side margin portion secured to the panel portion and being positioned between the outer layer and an inner layer.
 10. The carrier of claim 9 wherein at least one said carrier overlying and selectively engageable with an inner surface of said back panel and being movable relative thereto about a portion of the hinge member.
 11. The carrier as set forth in claim 6 wherein the containers including trays having recesses for receipt of memory devices therein.
 12. The carrier as set forth in claim 9 including a memory device removably mounted in a respective recess, said media device including at least one of a DVD or CD.
 13. A method of making a carrier for storing a plurality of memory devices, said method comprising: forming a jacket with a plurality of panels including a front panel, back panel, spine panel and panel portion, said panel portion being positioned adjacent a first side edge of the spine panel; forming a stack of plurality of containers, each container having a hinge edge; aligning the hinge edges in a said stack; applying a hinge member to the hinge edges of the containers in a stack to hingedly connect the containers in the stack together to form a hinged assembly; and securing the hinge member to the panel portion with the panel portion overlying and being secured to an exposed surface of the hinge member.
 14. The method of claim 13 wherein the stacks are positioned in end edge to end edge relationship prior to application of the hinge member.
 15. The method of claim 14 wherein the hinge member is formed from a strip of material which is applied to the hinge edges and then cut between abutting stacks of containers.
 16. The method of claim 15 wherein the strip of material is a double sided adhesive strip.
 17. The method of claim 13 wherein the panel portion is part of the back panel and having a free edge positioned adjacent and generally parallel to a side edge of the spine panel.
 18. The method of claim 17 forming the back panel from at least first and second layers with said panel portion being part of said first layer.
 19. The method of claim 18 wherein said panel portion being movable relative to the second layer at least prior to attachment of the hinge member to the panel portion.
 20. The method of claim 19 wherein a side edge margin portion of the hinge member being attached to the panel portion on a surface portion thereof between the first and second layers.
 21. The method of claim 20 wherein the panels are integral with one another. 